Solving the World’s Toughest CFD Problems

Continuous Casting Workspace Highlights

  • Advanced motion controls include vertical billet, horizontal pipe and roller sheet casting
  • Heat and cooling dynamic controls provide unsurpassed thermal management analysis
  • Complete simulation of fluid – solid transition in motion with advanced thermal stress analysis

Workspace Overview

The Continuous Casting Workspace provides continuous casting users with an easy-to-use tool for simulating all the commonly used foundry processes, including continuous billet casting as well as direct chill continuous casting. With the new Continuous Casting Workspace, users will find the tools they need to model their continuous casting process and optimize process parameters. Multi-block meshing provides an efficient method for even more accuracy in high shear and high temperature gradient regions of the casting. Process parameters such as mold and billet cooling, melt flow rate, superheat, and mold geometry are included in the analysis. Melt surface evolution and mold motion are quickly visualized during post-processing where fill and solidification patterns are also readily assessed, so that process modifications can be implemented with confidence.  


This simulation represents a direct chill continuous casting of a 0.8 m diameter cylindrical billet of bronze. The starter block, made of H13 steel, is withdrawn at a rate of 18 mm/min. A copper cooling jacket removes 200 kW of heat from the billet as it is withdrawn from the mold. Additional
cooling is applied to the billet surface after it leaves the mold. The video at the left shows the billet surface temperature, the middle video shows the solid fraction distribution in the billet, and the video at the right shows the temperature distributions in the melt and the mold, nozzle, cooling jacket, and starter block.

Processes modeled

  • Continuous billet and sheet casting
  • Direct chill continuous casting

Flexible Meshing

  • Multi-block meshing captures flow and temperature gradients

Thermal mold modeling

  • Localized die heating controls with heating and cooling elements
  • Convective and radiative heat transfer from melt and molds

Advanced solidification

  • Shrinkage
  • Directional solidification

Defect prediction

  • Porosity prediction
  • Entrained air
  • Early solidification
  • Oxide formation

Dynamic simulation control

  • Pour control based on flow dynamics

Complete analysis package

  • Animations with multi-viewports - 3D, 2D, history plots, volume rendering
  • Porosity analysis tool
  • Side-by-side simulation results comparison
  • Sensors for measuring melt temperature, solid fraction
  • Particle tracers
  • Batch post-processing
  • Report generation

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